Magnetic sensor with elongated soft magnetic body

ABSTRACT

A magnetic sensor detects a Z-axis magnetic field via a yoke and enhances the accuracy with which a magnetic field is detected. The magnetic sensor has a first magnetic field detecting element that is arranged in a plane that includes a first direction and a second direction. The second direction is perpendicular to the first direction. The first magnetic field detecting element detects a magnetic field in the first direction. In a soft magnetic body that is adjacent to the first magnetic field detecting element in the first direction, L/W is equal to or more than 10, where W is a length of the soft magnetic body in the first direction, and L is a length of the soft magnetic body in the second direction.

BACKGROUND OF THE INVENTION Field of the Invention

The present application is based on, and claims priority from, JP Applications No. 2017-181246, filed on Sep. 21, 2017 and 2018-103366, filed on May 30, 2018, the disclosure of which is hereby incorporated by reference herein in its entirety.

The present invention relates to a magnetic sensor, and particularly to the configuration of a yoke of the magnetic sensor.

Description of the Related Art

A magnetic sensor that includes a magneto-resistive effect element has been known. A magneto-resistive effect element has a magnetic field sensing film that detects a magnetic field. The magnetic field sensing film detects a magnetic field in an in-plane direction of the film. Recently, there is a need of a magnetic sensor that detects a magnetic field in a direction that is perpendicular to the in-plane direction of the magnetic field sensing film (hereinafter referred to as a Z-axis direction). JP5597206B discloses a magnetic sensor having a yoke that is formed of a soft magnetic material and that is provided adjacent to a magneto-resistive effect element. The yoke changes the direction of a Z-axis external magnetic field, which is absorbed by the yoke, to the in-plane direction of the magnetic field sensing film, thereby making it possible to detect a Z-axis magnetic field.

SUMMARY OF THE INVENTION

A magnetic sensor that detects an external magnetic field via a yoke causes hysteresis of the sensor output. Hysteresis is a phenomenon in which the sensor output for a magnetic field whose strength is increasing does not coincide with the sensor output for a magnetic field whose strength is decreasing at a certain magnetic field strength, thereby causing a difference of output between the former and the latter. A large hysteresis leads to deterioration of accuracy of the magnetic sensor.

An object of the present invention is to provide a magnetic sensor that detects a Z-axis magnetic field via a yoke and that enhances the accuracy with which a magnetic field is detected.

A magnetic sensor according to an embodiment comprises a first magnetic field detecting element that is arranged in a plane that includes a first direction and a second direction that is perpendicular to the first direction, wherein the first magnetic field detecting element detects a magnetic field in the first direction; and a soft magnetic body that is adjacent to the first magnetic field detecting element in the first direction. An aspect ratio L/W is equal to or more than 10, where W is a length of the soft magnetic body in the first direction, and L is a length of the soft magnetic body in the second direction.

A magnetic sensor according to another embodiment comprises a first magnetic field detecting element that is arranged in a plane that includes a first direction and a second direction that is perpendicular to the first direction, wherein the first magnetic field detecting element detects a magnetic field in the first direction; and a soft magnetic body that is adjacent to the first magnetic field detecting element in the first direction. An aspect ratio h/W satisfies 0.27=<h/W=<3, where W is a length of the soft magnetic body in the first direction, and h is a length of the soft magnetic body in a third direction that is perpendicular both to the first direction and the second direction.

According to the present invention, it is possible to provide a magnetic sensor that detects a Z-axis magnetic field via a yoke and that enhances the accuracy with which a magnetic field is detected.

The above and other objects, features and advantages of the present invention will become apparent from the following description with reference to the accompanying drawings which illustrate examples of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a conceptual perspective view of a magnetic sensor according to an embodiment of the present invention;

FIG. 2 is a cross sectional view of the magnetic sensor shown in FIG. 1 in a X-Z plane;

FIG. 3 is a conceptual cross sectional view showing the configuration of a magnetic field detecting sensor;

FIGS. 4A and 4B are schematic views showing hysteresis of a sensor output;

FIG. 5 is a graph showing a relationship between aspect ratio L/W and hysteresis;

FIG. 6 is a graph showing a relationship between aspect ratio h/W and hysteresis; and

FIGS. 7A and 7B are schematic views illustrating the mechanism in which hysteresis is limited in the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS

A magnetic sensor according to some embodiments of the present invention will be described with reference to the attached drawings. In the following descriptions, the first direction is a magnetic field sensing direction in which magnetic field detecting elements detect a magnetic field and the first direction also corresponds to the direction in which the magnetic field detecting elements are arranged. The second direction is perpendicular to the first direction. The first and second direction are parallel to a surface on which the magnetic field detecting elements are arranged. The third direction is perpendicular both to the first direction and the second direction and corresponds to a direction in which multiple films that constitute a magnetic field detecting element are stacked. The first direction, the second direction and the third direction are also called the X direction, the Y direction and the Z direction, respectively.

FIG. 1 shows a conceptual perspective view of magnetic sensor 1. Magnetic sensor 1 has first to fourth magnetic field detecting elements 2 a, 2 b, 2 c, 2 d that are arranged in first direction X. First to fourth magnetic field detecting elements 2 a, 2 b, 2 c, 2 d are arranged on a plane that includes first direction X and second direction Y and detects a magnetic field in first direction X. Each of first to fourth magnetic field detecting elements 2 a, 2 b, 2 c, 2 d has a substantially rectangular shape that is longer in second direction Y than in first direction X, as viewed in a plan view. First to fourth magnetic field detecting elements 2 a, 2 b, 2 c, 2 d are interconnected with each other by means of a bridge circuit (not shown), and thereby enabling magnetic sensor 1 to measure an external magnetic field.

First soft magnetic body 3 a is arranged between first magnetic field detecting element 2 a and second magnetic field detecting element 2 b, and second soft magnetic body 3 b is arranged between third magnetic field detecting element 2 c and fourth magnetic field detecting element 2 d. First and second soft magnetic bodies 3 a, 3 b are formed of NiFe or the like. First soft magnetic body 3 a is adjacent to first and second magnetic field detecting elements 2 a, 2 b in first direction X, and second soft magnetic body 3 b is adjacent to third and fourth magnetic field detecting element 2 c, 2 d in first direction X. First and second soft magnetic bodies 3 a, 3 b function as yokes that guide magnetic flux in third direction Z, that is absorbed by these soft magnetic bodies, to the magnetic field sensing direction of magnetic field detecting elements 2 a, 2 b, 2 c, 2 d, that is first direction X. Accordingly, first soft magnetic body 3 a and first yoke are interchangeably used, and second soft magnetic body 3 b and second yoke are interchangeably used in this specification. The external magnetic field that is inputted to first and second soft magnetic bodies 3 a, 3 b does not need to be exactly directed in first direction X as long as the component of first direction X is increased by the external magnetic field passing through first and second soft magnetic bodies 3 a, 3 b. First soft magnetic body 3 a preferably has a length that is larger than the lengths of first and second magnetic field detecting elements 2 a, 2 b in second direction Y and that contains first and second magnetic field detecting elements 2 a, 2 b, as seen in first direction X, in order to increase the component of first direction X along the entire lengths of first and second magnetic field detecting elements 2 a, 2 b in second direction Y. Similarly, second soft magnetic body 3 b preferably has a length that is larger than the lengths of third and fourth magnetic field detecting element 2 c, 2 d in second direction Y and that contains third and fourth magnetic field detecting element 2 c, 2 d, as seen in first direction X, in order to increase the component of first direction X along the entire lengths of third and fourth magnetic field detecting element 2 c, 2 d in second direction Y.

FIG. 2 shows a cross sectional view of magnetic sensor 1 in a X-Z plane cut along line A-A in FIG. 1. FIG. 2 only depicts first and second magnetic field detecting elements 2 a, 2 b and yoke 3 a, but third and fourth magnetic field detecting element 2 c, 2 d and yoke 3 b are constituted and arranged in the same manner as first and second magnetic field detecting elements 2 a, 2 b and first yoke 3 a, respectively. First and second magnetic field detecting elements 2 a, 2 b are formed above substrate 4 via first insulating layer 8. Second insulating layer 9 is formed on the lateral sides of first and second magnetic field detecting elements 2 a, 2 b. Third insulating layer 10 is formed on first and second magnetic field detecting elements 2 a, 2 b. First yoke 3 a is provided above third insulating layer 10. First yoke 3 a is formed by plating. Thus, electrode film 13 that is used in the plating process is interposed between third insulating layer 10 and first yoke 3 a. Fourth insulating layer 11 is formed on the lateral sides of first yoke 3 a. Fifth insulating layer 12 is formed on first yoke 3 a and fourth insulating layer 11. First to fifth insulating layers 8-12 are formed, for example, of Al₂O₃.

First magnetic field detecting element 2 a has first magnetic field sensing film 5 a that detects a magnetic field in first direction X and first pair of leads 6 a, 7 a that interpose first magnetic field sensing film 5 a in third direction Z and that supply a sensing current to first magnetic field sensing film 5 a. Second magnetic field detecting element 2 b has second magnetic field sensing film 5 b that detects a magnetic field in first direction X and second pair of leads 6 b, 7 b that interpose second magnetic field sensing film 5 b in third direction Z and that supply a sensing current to second magnetic field sensing film 5 b. The sensing current flows in third direction Z. First yoke 3 a is arranged between first magnetic field detecting element 2 a and second magnetic field detecting element 2 b in first direction X. As seen in Z direction, first yoke 3 a is arranged between pair of leads 6 a, 7 a of first magnetic field detecting element 2 a and pair of leads 6 b, 7 b of second magnetic field detecting element 2 b in X direction. In addition, first yoke 3 a does not overlap with pair of leads 6 a, 7 a of first magnetic field detecting element 2 a nor with pair of leads 6 b, 7 b of second magnetic field detecting element 2 b, as seen in Z direction.

Next, explanation will be given about first and second magnetic field detecting elements 2 a, 2 b. Since first magnetic field detecting element 2 a and second magnetic field detecting element 2 b have the same structure, first magnetic field detecting element 2 a will be explained here. FIG. 3 is a cross sectional view showing the structure of first magnetic field detecting element 2 a in more detail. First magnetic field sensing film 5 a of first magnetic field detecting element 2 a includes magnetization free layer 24, magnetization pinned layer 22 and spacer layer 23 that is interposed between magnetization free layer 24 and magnetization pinned layer 22 and that exhibits magneto-resistive effect. Magnetization free layer 24 is formed of a soft magnetic body, such as NiFe, and the magnetization direction thereof, when an external magnetic field is applied, is rotated in a plane that includes first direction X and second direction Y. Magnetization free layer 24 is sufficiently longer in second direction Y than in first direction X, and the magnetization direction is aligned in second direction Y due to the shape anisotropy effect. Bias layers that are formed of a hard magnetic material may be provided on both sides of magnetization free layer 24 in the Y direction in order to align the magnetization direction of magnetization free layer 24 in second direction Y. Magnetization pinned layer 22 is formed of a soft magnetic body, such as CoFe, and the magnetization direction is pinned relative to an external magnetic field. Spacer layer 23 is a tunneling barrier layer that is formed of a nonmagnetic insulating material, such as Al₂O₃. Accordingly, first magnetic field detecting element 2 a of this embodiment is a TMR (Tunnel Magneto Resistive) element. It should be noted that first magnetic field detecting element 2 a is not limited to a TMR element as long as it can detect a magnetic field in first direction X, and first magnetic field detecting element 2 a may be a magnetic field detecting element such as a GMR (Giant Magneto Resistive) element that utilizes a nonmagnetic metal layer, such as a Cu layer, for spacer layer 23 or an AMR (An-Isotropic Magneto Resistive) element.

Magnetization pinned layer 22 consists of first magnetization pinned layer 22 a, nonmagnetic intermediate layer 22 b and second magnetization pinned layer 22 c that are stacked in this order, with first magnetization pinned layer 22 a being formed on seed layer 21 that is formed of Ta or Ru. Second magnetization pinned layer 22 c is in contact with spacer layer 23. First magnetization pinned layer 22 a and second magnetization pinned layer 22 c are formed of a soft magnetic body, such as CoFe, and nonmagnetic intermediate layer 22 b is formed of Ru. First magnetization pinned layer 22 a and second magnetization pinned layer 22 c are anti-ferromagnetically coupled to each other via nonmagnetic intermediate layer 22 b. An anti-ferromagnetic layer (not shown) that is formed, for example, of IrMn, and that exchange-couples with first magnetization pinned layer 22 a may be provided under first magnetization pinned layer 22 a. Magnetization free layer 24 is covered with protection layer 25 that is formed of Ta or the like.

When an external magnetic field is applied to magnetic sensor 1 thus constructed in third direction Z, magnetic flux is absorbed by first yoke 3 a (shown with the bold arrows in FIG. 2) and is bent in first direction X before exiting first yoke 3 a. Since a magnetic field whose component in first direction X increases after the magnetic field passes through first yoke 3 a is applied to first and second magnetic field detecting elements 2 a, 2 b, magnetic field in first direction X can be more effectively detected, as compared to a magnetic sensor that does not have first yoke 3 a. Therefore, it is possible for magnetic sensor 1 to detect an external magnetic field in third direction Z that corresponds to the magnetic field strength in first direction X.

One of the characteristics of a magnetic sensor that detects an external magnetic field after the external magnetic field passes through a yoke that is formed of a soft magnetic body is that there is hysteresis in the sensor output. FIG. 4A schematically illustrates a relationship between an external magnetic field and a sensor output, and FIG. 4B shows an enlarged view of part A in FIG. 4A. V1(H) is sensor output when external magnetic field H whose strength is increasing in the third direction is applied to a yoke, and V2(H) is sensor output when external magnetic field H whose strength is decreasing in the third direction is applied to a yoke. The sensor output is a function of external magnetic field H. It is preferred that V1(H) completely coincide with V2(H), but actually, V1(H) does not completely coincide with V2(H). This means that external magnetic field H has a range within which ΔV=|V1(H)−V2(H)| is not zero. When ΔV is not zero, magnetic sensor 1 outputs V1(H) or V2(H) depending on whether the strength of the external magnetic field is increasing or decreasing. Therefore, when ΔV is large, the accuracy of magnetic sensor 1 deteriorates.

Magnetic sensor 1 of the present embodiment is characterized by the dimensions or the shape of first soft magnetic body 3 a that is able to decrease the hysteresis of the sensor output. The dimensions or the shape of second soft magnetic body 3 b may be the same as that of first soft magnetic body 3 a, but may be different from that of first soft magnetic body 3 a as long as the dimensions or the shape have the following characteristics. Examination will be given about first soft magnetic body 3 a as an example. First soft magnetic body 3 a has a substantially rectangular parallelepiped shape. Suppose that W is the length (width) of first soft magnetic body 3 a in first direction X, L is the length of first soft magnetic body 3 a in second direction Y and h is the length (height) of first soft magnetic body 3 a in third direction Z.

FIG. 5 is a graph showing a relationship between aspect ratio L/W and Hymax, in which the axis of abscissas denotes L/W and the axis of ordinates denotes Hymax. Hy is defined as the ratio of ΔV to output range Vrange (=ΔV/Vrange), showing the magnitude of hysteresis relative to output range Vrange. Output range Vrange is differential VH−VL, where VH and VL are two saturation points of sensor output V. Saturation point VH is defined to be sensor output V1(H) that is outputted when the changing ratio of sensor output V1(H) to external magnetic field H whose component in third direction Z is increasing with time becomes half of the maximum changing ratio. Similarly, saturation point VL is defined to be sensor output V2(H) that is outputted when the changing ratio of sensor output V2(H) to external magnetic field H whose component in third direction Z is decreasing with time becomes half of the maximum changing ratio. Here, VH>VL. By changing external magnetic field H between external magnetic fields HL and HH (see FIGS. 4A and 4B) that correspond to VL and VH, respectively, ΔV is calculated for each value of H. The axis of ordinates in FIG. 5 denotes maximum value Hymax of Hy=ΔV/Vrange. In other words, Hymax is defined to be

${{Hy}\mspace{20mu}\max} = {\frac{\Delta\; V\mspace{14mu}\max}{Vrange} = \frac{{{{V\; 1(H)} - {V\; 2(H)}}}\max}{{VH} - {VL}}}$

V1(H) is the sensor output when external magnetic field H whose component in third direction Z is increasing with time is applied to first soft magnetic body 3 a, and V2(H) is the sensor output when external magnetic field H whose component in third direction Z is decreasing with time is applied to first soft magnetic body 3 a.

In FIG. 5, width W is a variable while length L of first soft magnetic body 3 a is a constant (78 μm). The approximation curve that shows the relationship between aspect ratio L/W and Hymax is approximated by a polynomial. The upper limit of Hymax is preferably set to be about 1.25%. Magnetic sensor 1 of the present embodiment may be used, for example, to detect the position of a lens of a camera module. When Hymax is 1.25%, the error in detecting the position of a lens that is movable, for example, within +−200 μm can be limited to 5 μm or less. This level of accuracy is satisfactory for a general camera module. From FIG. 5, L/W is preferably equal to or more than 10. Although Hymax is decreased with an increase of L/W, Hymax is substantially saturated in the range of L/W of 20 or more, and Hymax can be limited to a sufficiently low level. Accordingly, L/W is more preferably equal to or more than 20. Since Hymax is saturated as L/W becomes large, it is not effective to set L/W extremely large. On the other hand, increasing L/W leads to an increase of length L and may affect the outer dimensions of magnetic sensor 1 since reducing width W is difficult because of the manufacturing reasons. Accordingly, L/W is preferably equal to or less than 40.

FIG. 6 is a graph showing a relationship between aspect ratio L/h and Hymax, in which the axis of abscissas denotes h/W and the axis of ordinates denotes Hymax. Hymax is calculated in the same manner as in FIG. 5. Width W of first soft magnetic body 3 a is a variable while length L is a constant (78 μm) and height h is a constant (2.5 μm). The approximation curve that shows the relationship between aspect ratio h/W and Hymax is approximated by a polynomial.

Referring to FIG. 6, h/W is preferably equal to or more than 0.27. Hymax is decreased as h/W becomes large. However, increasing h/W requires decreasing width W or increasing height h, and both are difficult because of the manufacturing reasons. Accordingly, the upper limit of h/W is preferably set to be 3. In addition, since Hymax tends to be saturated as h/W becomes large, h/W is preferably set to satisfy the formula: about 0.27=<h/W<about 1.5 from practical point of view.

First soft magnetic body 3 a may have various shapes other than rectangular parallelepiped. In general, either one of a side that extends in first direction X, a side that extends in second direction Y or a side that extends in third direction Z may be nonlinear or may be a curve or may be a combination of a curve and a straight line. Alternatively, first soft magnetic body 3 a may be asymmetrical with regard to at least either one of first direction X, second direction Y and third direction Z. In this case, length (width) W in first direction X may be defined as an average that is taken along second direction Y or third direction Z. When a constant width portion occupies a majority in second direction Y or in third direction Z, width W may be defined to be the width of the constant width portion. The same can be applied to length L in second direction Y and length (height) h in third direction Z.

The reason why the hysteresis of the sensor output can be limited by adjusting the ranges of L/W and h/W will be summarized below. FIG. 7A is a conceptual view of a magnetic sensor according to a comparative example, as seen in third direction Z, and FIG. 7B is a conceptual view of a magnetic sensor according to the present embodiment, as seen in third direction Z. Yoke 103 a of the comparative example and yoke 3 a of the present embodiment are divided into a plurality of magnetic domains. An example of the magnetization directions of the magnetic domains is illustrated in the figures. In the comparative example, magnetization directions of the magnetic domains are randomly distributed in first direction X, second direction Y and third direction Z. When an external magnetic field is applied to the yoke in this state in the third direction, hysteresis of sensor output easily occurs. On the other hand, it is assumed in the present embodiment, in which the ranges of L/W and h/W are set as described above, that the magnetization of yoke 3 a tends to be uniformly changed when the magnetic field is changed, and thus, hysteresis is limited.

Although certain preferred embodiments of the present invention have been shown and described in detail, it should be understood that various changes and modifications may be made without departing from the spirit or scope of the appended claims.

LIST OF REFERENCE NUMERALS

-   -   1 Magnetic sensor     -   2 a, 2 b, 2 c, 2 d First to Fourth Magnetic Field Detecting         Element     -   3 a, 3 b First and Second Soft Magnetic Body (Yoke)     -   W Length (Width) of Yoke in First Direction X     -   L Length of Yoke in Second Direction Y     -   h Length (Height) of Yoke in Third direction Z 

What is claimed is:
 1. A magnetic sensor comprising: a first magnetic field detecting element that is arranged in a plane that includes a first direction and a second direction that is perpendicular to the first direction, wherein the first magnetic field detecting element detects a magnetic field in the first direction; and a soft magnetic body that is adjacent to the first magnetic field detecting element in the first direction, wherein L/W is equal to or more than 10, where W is a length of the soft magnetic body in the first direction, and L is a length of the soft magnetic body in the second direction, the magnetic sensor further comprises a second magnetic field detecting element that is arranged in a plane that includes the first direction and the second direction, wherein the second magnetic field detecting element detects a magnetic field in the first direction, each of the first and second magnetic field detecting elements has a magnetic field sensing film that detects a magnetic field in the first direction and a pair of leads that interpose the magnetic field sensing film in a third direction that is perpendicular both to the first direction and to the second direction, and the soft magnetic body is positioned between the pair of leads of the first magnetic field detecting element and the pair of leads of the second magnetic field detecting element and does not overlap with the pair of leads of the first magnetic field detecting element nor with the pair of leads of the second magnetic field detecting element, as seen in the third direction.
 2. The magnetic sensor according to claim 1, wherein L/W is equal to or more than
 20. 3. The magnetic sensor according to claim 1, wherein 0.27=<h/W=<3, where h is a length of the soft magnetic body in a third direction that is perpendicular both to the first direction and to the second direction.
 4. The magnetic sensor according to claim 1, wherein $\frac{{{{V\; 1(H)} - {V\; 2(H)}}}\max}{{VH} - {VL}} \leq {1.25\%}$ where V1(H) is sensor output when external magnetic field whose strength is increasing in a third direction that is perpendicular both to the first direction and to the second direction, V2(H) is sensor output when external magnetic field whose strength is decreasing in the third direction and VH and VL are two saturation points of the sensor output.
 5. A magnetic sensor comprising: a first magnetic field detecting element that is arranged in a plane that includes a first direction and a second direction that is perpendicular to the first direction, wherein the first magnetic field detecting element detects a magnetic field in the first direction; and a soft magnetic body that is adjacent to the first magnetic field detecting element in the first direction, wherein 0.27=<h/W=<3, where W is a length of the soft magnetic body in the first direction, h is a length of the soft magnetic body in a third direction that is perpendicular both to the first direction and to the second direction, the magnetic sensor further comprises a second magnetic field detecting element that is arranged in a plane that includes the first direction and the second direction, wherein the second magnetic field detecting element detects a magnetic field in the first direction, each of the first and second magnetic field detecting elements has a magnetic field sensing film that detects a magnetic field in the first direction and a pair of leads that interpose the magnetic field sensing film in a third direction that is perpendicular both to the first direction and to the second direction, and the soft magnetic body is positioned between the pair of leads of the first magnetic field detecting element and the pair of leads of the second magnetic field detecting element and does not overlap with the pair of leads of the first magnetic field detecting element nor with the pair of leads of the second magnetic field detecting element, as seen in the third direction.
 6. The magnetic sensor according to claim 5, wherein 0.27=<h/W=<1.5.
 7. The magnetic sensor according to claim 5, wherein L/W is equal to or more than 10, where L is a length of the soft magnetic body in the second direction.
 8. The magnetic sensor according to claim 5, wherein $\frac{{{{V\; 1(H)} - {V\; 2(H)}}}\max}{{VH} - {VL}} \leq {1.25\%}$ where V1(H) is sensor output when external magnetic field whose strength is increasing in a third direction that is perpendicular both to the first direction and to the second direction, V2(H) is sensor output when external magnetic field whose strength is decreasing in the third direction and VH and VL are two saturation points of the sensor output. 